IP Library Granted Patent US 10,742,165
Granted Patent B2
US 10,742,165 · App. 15/647,213 · Granted Aug 11, 2020

Bypass mechanisms for energy generation systems

Inventors: Brian Edward Atchley (Petaluma, CA); David Molina (Oakland, CA); Steve Pisklak (Hockessin, DE); Johann Fritz Karkheck (Petaluma, CA); Greg Ball (Fairfax, CA)
Assignee: SolarCity Corporation
H02S40/36H01L31/0201H01L31/042H02H7/20H02S20/23H02S20/25H02S40/32H02S40/34
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Quick Facts
Patent No.
US 10,742,165
App. No.
15/647,213
Granted
Aug 11, 2020
Kind
B2
Abstract

A photovoltaic (PV) module sub-circuit for an energy generation system includes a plurality of PV sub-modules coupled together via external cables, the plurality of PV sub-modules includes a first PV sub-module and a second PV sub-module, a negative output terminal coupled to the first PV sub-module, a positive output terminal coupled to the second PV sub-module, and a plurality of connectors external to the PV sub-modules and coupling the PV sub-modules together to form the PV module sub-circuit. The sub-circuit further includes a bypass mechanism including a first terminal coupled to only the negative output terminal and the first PV sub-module, and a second terminal coupled to only the positive output terminal and the second PV sub-module, the bypass mechanism configured to prevent current flow in a first direction and allow current flow in a second direction opposite of the first direction.

Claims (34)

1. A photovoltaic (PV) module string for an energy generation system comprising:

a plurality of PV module sub-circuits, each PV module sub-circuit of the plurality of PV module sub-circuits comprising:

a plurality of PV sub-modules coupled together via external cables, the plurality of PV sub-modules comprising a first PV sub-module and a second PV sub-module;

a negative output terminal coupled to the first PV sub-module of the plurality of PV sub-modules;

a positive output terminal coupled to the second PV sub-module of the plurality of PV sub-modules;

a plurality of connectors external to the PV sub-modules and coupling the PV sub-modules together to form the PV module sub-circuit so that a current flows through the connectors and the external cables during energy generation; and

a sub-circuit bypass mechanism comprising a first terminal coupled to only the negative output terminal and the first PV sub-module, and a second terminal coupled to only the positive output terminal and the second PV sub-module, the sub-circuit bypass mechanism configured to prevent current flow in a first direction and allow current flow in a second direction opposite of the first direction when a voltage across the sub-circuit bypass mechanism increases above a first voltage threshold to prevent an occurrence of a thermal event; and

a system bypass mechanism coupled to the negative output terminal of a first PV module sub-circuit of the plurality of PV module sub-circuits and to the positive output terminal of a second PV module sub-circuit of the plurality of PV module sub-circuits, the system bypass mechanism configured to prevent current flow in a third direction and allow current flow in a fourth direction opposite of the third direction when a voltage across the system bypass mechanism increases above a second voltage threshold.

2. The PV module string of claim 1 , wherein the sub-circuit bypass mechanism is a passive electrical device.

3. The PV module string of claim 2 , wherein the passive electrical device is a diode.

4. The PV module string of claim 3 , wherein an anode of the diode is coupled to the negative output terminal and a cathode of the diode is coupled to the positive output terminal.

5. The PV module string of claim 1 , wherein the bypass mechanism is an active electrical device.

6. The PV module string of claim 5 , wherein the bypass mechanism is a power electronic circuit.

7. The PV module string of claim 6 , wherein the power electronic circuit comprises a sensor, a switch, and a controller coupled to the sensor and the switch and configured to control the switch based on data received from the sensor.

8. The PV module string of claim 6 , wherein the power electronic circuit is incorporated in an optimizer for performing maximum power point tracking of power outputted by the plurality of PV sub-modules.

9. The PV module string of claim 1 , wherein each of the PV sub-modules comprises at least two PV cells.

10. The PV module string of claim 1 , wherein the PV sub-module is a PV shingle that has a structure and an appearance of a roof shingle.

11. The PV module string sub-circuit of claim 1 , wherein the thermal event is an occurrence of an electrical arcing or overheating.

12. A building-integrated photovoltaic (PV) energy generation system comprising:

a plurality of PV module sub-circuits coupled together and configured to output power to a pair of terminals, each PV module sub-circuit comprising:

a plurality of PV sub-modules coupled together via external cables, the plurality of PV sub-modules comprising a first PV sub-module and a second PV sub-module;

a negative output terminal coupled to the first PV sub-module of the plurality of PV sub-modules;

a positive output terminal coupled to the second PV sub-module of the plurality of PV sub-modules;

a plurality of connectors external to the PV sub-modules and coupling the PV sub-modules together to form the PV module sub-circuit so that a current flows through the connectors and the external cables during energy generation; and

a sub-circuit bypass mechanism comprising a first terminal coupled to only the negative output terminal and the first PV sub-module, and a second terminal coupled to only the positive output terminal and the second PV sub-module, the bypass mechanism configured to prevent current flow in a first direction and allow current flow in a second direction opposite of the first direction when a voltage across the sub-circuit bypass mechanism increases above a voltage threshold;

a system bypass mechanism coupled to the negative output terminal of a first PV module sub-circuit of the plurality of PV module sub-circuits and to the positive output terminal of a second PV module sub-circuit of the plurality of PV module sub-circuits, the system bypass mechanism configured to prevent current flow in a third direction and allow current flow in a fourth direction opposite of the third direction when a voltage across the system bypass mechanism increases above a second voltage threshold; and

an inverter coupled to the plurality of PV module sub-circuits via the pair of terminals and configured to receiver power from the plurality of PV module sub-circuits.

13. The energy generation system of claim 12 , wherein the sub-circuit bypass mechanism is a diode.

14. The energy generation system of claim 13 , wherein an anode of the diode is coupled to the negative output terminal of the PV module sub-circuit and a cathode of the diode is coupled to the positive output terminal of the PV module sub-circuit.

15. The energy generation system of claim 12 , wherein the sub-circuit bypass mechanism is a power electronic circuit.

16. The energy generation system of claim 15 , wherein the power electronic circuit comprises a sensor, a switch, and a controller coupled to the sensor and the switch and configured to control the switch based on data received from the sensor.

17. The energy generation system of claim 12 , wherein each of the PV sub-modules comprises at least two PV cells.

18. The energy generation system of claim 12 , wherein each of the PV sub-modules is a PV roof tile that has a structure and an appearance of a roof tile.

19. The energy generation system of claim 12 , wherein the sub-circuit bypass mechanism is configured to prevent an occurrence of a thermal event caused by electrical arcing or overheating.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 6, 2021
From: SOLARCITY CORPORATION
To: TESLA, INC.
Reel/Frame 056172/0062 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 11, 2017
From: ATCHLEY, BRIAN EDWARD; MOLINA, DAVID; PISKLAK, STEVE; KARKHECK, JOHANN FRITZ; BALL, GREG
To: SOLARCITY CORPORATION
Reel/Frame 042979/0886 →
Continuity (1)
Related Publication 20190020306A1 · Jan 17, 2019